EP3237199B1 - Folie und dekorative folie zur abdeckung eines artikels mit dreidimensionaler form durch wärmeausdehnung - Google Patents

Folie und dekorative folie zur abdeckung eines artikels mit dreidimensionaler form durch wärmeausdehnung Download PDF

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Publication number
EP3237199B1
EP3237199B1 EP15826100.8A EP15826100A EP3237199B1 EP 3237199 B1 EP3237199 B1 EP 3237199B1 EP 15826100 A EP15826100 A EP 15826100A EP 3237199 B1 EP3237199 B1 EP 3237199B1
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EP
European Patent Office
Prior art keywords
layer
film
polyurethane
approximately
thermal adhesive
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EP15826100.8A
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English (en)
French (fr)
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EP3237199A1 (de
Inventor
Yorinobu Takamatsu
Akihiko Nakayama
Daigo Yasuda
Minori KAWAGOE
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3M Innovative Properties Co
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3M Innovative Properties Co
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Priority to PL15826100T priority Critical patent/PL3237199T3/pl
Publication of EP3237199A1 publication Critical patent/EP3237199A1/de
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/22—Layered products comprising a layer of synthetic resin characterised by the use of special additives using plasticisers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B32B27/365—Layered products comprising a layer of synthetic resin comprising polyesters comprising polycarbonates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
    • B32B37/025—Transfer laminating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/18—Handling of layers or the laminate
    • B32B38/1825—Handling of layers or the laminate characterised by the control or constructional features of devices for tensioning, stretching or registration
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/18—Handling of layers or the laminate
    • B32B38/1866—Handling of layers or the laminate conforming the layers or laminate to a convex or concave profile
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
    • B32B2037/243—Coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/26—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer which influences the bonding during the lamination process, e.g. release layers or pressure equalising layers
    • B32B2037/268—Release layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B2038/0052—Other operations not otherwise provided for
    • B32B2038/0088—Expanding, swelling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/20—Inorganic coating
    • B32B2255/205—Metallic coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2270/00—Resin or rubber layer containing a blend of at least two different polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2274/00—Thermoplastic elastomer material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/302—Conductive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/308—Heat stability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/402—Coloured
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/402—Coloured
    • B32B2307/4026—Coloured within the layer by addition of a colorant, e.g. pigments, dyes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/738—Thermoformability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/75—Printability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/60—In a particular environment
    • B32B2309/68—Vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2451/00—Decorative or ornamental articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/14—Printing or colouring
    • B32B38/145—Printing

Definitions

  • the present disclosure relates to a film, in particular to a decorative film capable of covering an article having a three-dimensional shape, and more particularly to so covering a three-dimensional article with such a film by heat expansion.
  • a decorative film is effective in improving a work environment because there are no volatile organic compounds (VOC) or any spray mist.
  • Insert molding (IM), water transfer, the three-dimensional overlay method (TOM) and the like have generally been used as methods for applying these decorative films.
  • the decorative film By heating and stretching a decorative film using these methods to make it conform to an article surface, the decorative film can be applied to an article having a three-dimensional shape such as a molded part without defects, and sufficient adhesion to the article can be obtained immediately after application of the decorative film.
  • Japanese Unexamined Patent Application Publication No. 2009-035588A describes "an adhesive film comprising a substrate and an adhesive layer on the substrate, the adhesive layer comprising (A) a (meth)acrylic polymer containing a carboxyl group, in which the proportion of the number of repeating units containing a carboxyl group relative to the total number of repeating units of the polymer is from 4.0 to 25%, and having a glass transition temperature (Tg) of not higher than 25°C, and (B) a (meth)acrylic polymer containing an amino group, in which the proportion of the number of repeating units containing an amino group relative to the total number of repeating units of the polymer is from 3.5 to 15%, and having a glass transition temperature (Tg) of not lower than 75°C, wherein the blending ratio of component (A) and component (B) is from 62:38 to 75:25 by weight.”
  • Japanese Unexamined Patent Application No. 2004-284019A describes a glitter sheet obtained by laminating a base material layer and a glitter layer, the glitter layer contains glitter glass flakes coated with at least one kind of a substance selected from the group consisting of a metal and a metal oxide and comprises a thermoplastic resin of which the heat-shrinkage stress at least in one of the longitudinal and lateral directions of the glitter layer is 0.1-1 MPa, wherein the base material layer is based on a polypropylene resin and an adhesive layer is provided between the base material layer and the glitter layer.
  • EP 2 689 929 discloses a decorative sheet for three-dimensional molding which includes a thin metal film layer, a surface protection layer, and a base film, at least the thin metal film layer and the surface protection layer being disposed on the base film in this order, in which the surface protection layer consists of a cured material of an ionizing radiation curable resin composition containing a polycarbonate(meth)acrylate and/or an acrylic silicone (meth)acrylate.
  • EP 2 752 294 discloses a decorative sheet which comprises, on a base film layer, a second picture layer that is partially provided and a surface protective layer that is present on and in contact with the second picture layer and covers the entire surface of the base film layer including the region where the second picture layer is formed and the region where the second picture layer is not formed, wherein a binder resin for a second picture ink that constitutes the second picture layer is a thermoplastic resin; the surface protective layer is formed of a crosslinking-cured product of an ionizing radiation curable resin composition that contains a polycarbonate (meth)acrylate and/or an acrylic silicone (meth)acrylate; and a low gloss pattern layer that has a low luster region is formed in the surface protective layer right above the second picture layer by the interaction between the ionizing radiation curable resin and the thermoplastic resin.
  • WO 2012/005097 discloses a biaxially oriented polyexter film for molding, wherein the 100% elongation stress (F100 value) in the lengthwise direction and widthwise direction of the film at 150°C are each at least 5 MPa and less than 60 MPa, and the storage modulus in the lengthwise direction and widthwise direction of the film at 80°C are each at least 2001 MPa and less than 4000 MPa, and the storage modulus in the lengthwise direction and widthwise direction of the film at 180°C are each at least 41 MPa and less than 400 MPa.
  • F100 value 100% elongation stress in the lengthwise direction and widthwise direction of the film at 150°C are each at least 5 MPa and less than 60 MPa
  • the storage modulus in the lengthwise direction and widthwise direction of the film at 80°C are each at least 2001 MPa and less than 4000 MPa
  • the storage modulus in the lengthwise direction and widthwise direction of the film at 180°C are each at least 41 MPa and less than 400 MPa.
  • the adhesive film described in Japanese Unexamined Patent Application Publication No. 2009-035588A requires primer treatment or a primer layer on the surface of an article containing polycarbonate (PC) or acrylonitrile/butadiene/styrene copolymer (ABS).
  • PC polycarbonate
  • ABS acrylonitrile/butadiene/styrene copolymer
  • TOM a film application temperature of, for example, from approximately 120°C to approximately 150°C is reached by heating only the applied film using an IR lamp or the like, but it is generally considered to be difficult to achieve good adhesion without using a primer because the product is not sufficiently heated and its surface remains at a relatively low temperature.
  • IM a film that has been three-dimensionally processed in advance as necessary is heated in a molding die, and by injecting material fused to the surface of the film, an article in which the film and the injected material are integrated in one piece is obtained, but there are cases where sufficient adhesion is not obtained depending on the combination of the adhesive layer of the film and the injected material.
  • the present disclosure provides a film and a decorative film which exhibit excellent adhesive strength to articles or materials containing PC or ABS even without primer treatment being performed when used in IM or TOM.
  • One embodiment of the present disclosure provides a film capable of covering an article having a three-dimensional shape by heat expansion, the film comprising an outermost layer disposed on an outermost surface, and a polyurethane thermal adhesive layer, which contains a thermoplastic polyurethane selected from the group consisting of polyester-based polyurethanes and polycarbonate-based polyurethanes and is thermally adhered to the article during the heat expansion, wherein the fracture strength of the polyurethane thermal adhesive layer is not less than 1 MPa at 135°C, and the storage modulus at 150°C and frequency 1.0 Hz is from 5 ⁇ 10 3 Pa to 5 ⁇ 10 5 Pa, and the coefficient of loss tan8 is not less than 0.1.
  • a polyurethane thermal adhesive layer which contains a thermoplastic polyurethane selected from the group consisting of polyester-based polyurethanes and polycarbonate-based polyurethanes and is thermally adhered to the article during the heat expansion, wherein the fracture strength of the polyurethane thermal adhesive layer is not
  • Another embodiment of the present disclosure provides a decorative film capable of covering an article having a three-dimensional shape by heat expansion, the film comprising an outermost layer disposed on an outermost surface, and a polyurethane thermal adhesive layer, which contains a thermoplastic polyurethane selected from the group consisting of polyester-based polyurethanes and polycarbonate-based polyurethanes and is thermally adhered to the article during the heat expansion, and a design layer disposed between the outermost layer and the polyurethane thermal adhesive layer, wherein the fracture strength of the polyurethane thermal adhesive layer is not less than 1 MPa at 135°C, and the storage modulus at 150°C and frequency 1.0 Hz is from 5 ⁇ 10 3 Pa to 5 ⁇ 10 5 Pa, and the coefficient of loss tan8 is not less than 0.1.
  • a polyurethane thermal adhesive layer which contains a thermoplastic polyurethane selected from the group consisting of polyester-based polyurethanes and polycarbonate-based polyurethanes and is thermally adhered to
  • Yet another embodiment of the present disclosure provides an article obtained by covering and integrating an article with the film or the decorative film described above.
  • the film and decorative film of the present disclosure can achieve excellent adhesion to an article containing PC, ABS, or a mixture or blend thereof even without a primer treatment being performed when used in IM or TOM.
  • film also encompasses laminates called “sheets” having flexibility.
  • the three-dimensional overlay method means a molding method including a step of preparing a film and an article having a three-dimensional shape, a step of disposing the film and the article in a vacuum chamber having a heating device on the interior, wherein the film separates the interior space of the vacuum chamber into two and the article is disposed in one of the separated interior spaces, a step of heating the film by the heating device, a step of putting both the interior space in which the article is disposed and the interior space on the opposite side thereof in a vacuum atmosphere, and a step of contacting the article with the film to cover the article with the film while putting the interior space in which the article is disposed in a vacuum atmosphere and putting the interior space on the opposite side thereof in a pressurized atmosphere or normal-pressure atmosphere.
  • (meth)acrylic refers to “acrylic or methacrylic”
  • (meth)acrylate refers to “acrylate or methacrylate.”
  • storage modulus is the shear storage modulus G' when viscoelasticity measurement is performed in shear mode at frequency 1.0 Hz at a prescribed temperature using a dynamic viscoelasticity measurement device.
  • Coefficient of loss (tan ⁇ ) is the ratio of shear loss modulus G"/shear storage elastic modulus G'.
  • the film capable of covering an article having a three-dimensional shape by heat expansion (also referred to simply as "heat-expanding film” in the present disclosure) of one embodiment of the present disclosure contains an outermost layer disposed on the outermost surface, and a polyurethane thermal adhesive layer, which contains a thermoplastic polyurethane selected from the group consisting of polyester-based polyurethanes and polycarbonate-based polyurethanes and is thermally adhered to the article during heat expansion.
  • the fracture strength of the polyurethane thermal adhesive layer is not less than approximately 1 MPa at 135°C, and the storage modulus at 150°C and frequency 1.0 Hz is from approximately 5 ⁇ 10 3 Pa to approximately 5 ⁇ 10 5 Pa, and the coefficient of loss tan8 is not less than approximately 0.1.
  • FIG. 1 illustrates a cross-sectional view of a heat-expanding film 10 according to an embodiment of the present disclosure.
  • the heat-expanding film 10 contains an outermost layer 11 and a polyurethane thermal adhesive layer 12.
  • the heat-expanding film 10 may also contain additional layers such as a design layer, a metal brightening layer, a substrate layer and a bonding layer.
  • the heat-expanding film 10 of another embodiment of the present disclosure illustrated in FIG. 2 additionally has a design layer 13 disposed between the outermost layer 11 and the polyurethane thermal adhesive layer 12.
  • the heat-expanding film having a design layer is also called a "decorative film capable of covering an article having a three-dimensional shape by heat expansion" or a "heat-expanding decorative film.”
  • descriptions relating to the "heat-expanding film” in the present disclosure also apply to the "heat-expanding decorative film.”
  • the heat-expanding film 10 of another embodiment of the present disclosure illustrated in FIG. 3 additionally has a metal brightening layer 14 disposed on the polyurethane thermal adhesive layer 12 between the outermost layer 11 and the polyurethane thermal adhesive layer 12.
  • the number of layers, the type, the arrangement and so forth of the heat-expanding film are not limited to those described above.
  • acrylic resins such as polymethyl methacrylate (PMMA) and (meth)acrylic copolymer
  • fluorine resins such as polyurethane, ethylene/tetrafluoroethylene copolymer (ETFE), polyvinylidene fluoride (PVDF), methyl methacrylate/vinylidene fluoride copolymer (PMMA/PVDF), polyolefins such as polyvinyl chloride (PVC), polycarbonate (PC), polyethylene (PE) and polypropylene (PP), polyesters such as polyethylene terephthalate (PET) and polyethylene naphthalate, and copolymers such as ethylene/acrylic acid copolymer (EAA) and ionomers thereof, ethylene/ethyl acrylate copolymer, ethylene/vinyl acetate copolymer, and the like can be used.
  • acrylic resins such as polymethyl methacrylate (PMMA) and (meth)acrylic copolymer
  • the outermost layer may also have a multi-layer structure.
  • the outermost layer may be a laminate of films formed from the above resins, or it may by a multi-layer coating of the above resins.
  • the outermost layer may be formed by coating a resin composition on another layer that constitutes the heat-expanding film, such as a polyurethane thermal adhesive layer, a design layer of any constituent element, a metal brightening layer, a substrate layer, a bonding layer or the like.
  • a resin composition on another layer that constitutes the heat-expanding film
  • an outermost layer film can be formed by coating the resin composition on a different liner, and that film can be laminated on another layer via a bonding layer. If the polyurethane thermal adhesive layer, the design layer, the metal brightening layer, and the substrate layer and the like are adhesive to the outermost layer film formed on the liner, the outermost layer film can be laminated directly onto these layers without having a bonding layer therebetween.
  • the outermost layer film can be formed by coating resin material such as a curable acrylic resin composition, reactive polyurethane composition, or the like on a liner or the like using knife coating, bar coating, blade coating, doctor coating, roll coating, cast coating and the like, and then heat curing as necessary.
  • resin material such as a curable acrylic resin composition, reactive polyurethane composition, or the like
  • An outermost layer formed into a film beforehand through extrusion, drawing and the like may be used.
  • This type of film can be laminated on the design layer, metal brightening layer, substrate layer, and the like via a bonding layer.
  • the film can be laminated directly onto these layers without having a bonding layer therebetween.
  • the outermost layer can be formed by multi-layer extrusion with other layers.
  • a resin containing polymethyl methacrylate (PMMA), butyl polyacrylate, (meth)acrylic copolymer, ethylene/acrylic copolymer, ethylene vinyl acetate/acrylic copolymer resin, and the like can be formed into a film and used as an acrylic film.
  • An acrylic film has excellent transparency, is resistant to heat and light, and will not easily cause discoloration or luster change when used outdoors. Also, an acrylic film is further characterized by excellent contamination resistance without the use of a plasticizer and the ability to be processed by deep drawing due to excellent moldability. It is particularly preferable to make PMMA the main component.
  • the outermost layer may have a variety of thicknesses, but it is generally not less than approximately 1 ⁇ m, not less than approximately 5 ⁇ m, or not less than approximately 10 ⁇ m, and not more than approximately 200 ⁇ m, not more than approximately 100 ⁇ m, or not more than approximately 80 ⁇ m.
  • a thin outermost layer is advantageous; for example, a thickness of not more than approximately 100 ⁇ m or not more than approximately 80 ⁇ m is preferable.
  • a thick outermost layer is more advantageous in terms of giving the structure high light resistance and/or weather resistance; for example, not less than approximately 5 ⁇ m or not less than approximately 10 ⁇ m is preferable.
  • the outermost layer may include, as necessary, ultraviolet absorbers such as benzotriazole, Tinuvin 1130 (manufactured by BASF), and the like, and hindered amine light stabilizers (HALS) such as Tinuvin 292 (manufactured by BASF), and the like.
  • ultraviolet absorbers such as benzotriazole, Tinuvin 1130 (manufactured by BASF), and the like
  • hindered amine light stabilizers HALS
  • the outermost layer may include a hard coating material, a luster-imparting agent, and the like, and may also have an additional hard coating layer. In order to provide an intended appearance, the outermost layer may be transparent, semitransparent, or opaque. It is advantageous if the outermost layer is transparent.
  • the polyurethane thermal adhesive layer functions so as to adhere the heat-expanding film to the article that is to be adhered to during heat expansion.
  • the polyurethane thermal adhesive layer contains a thermoplastic polyurethane selected from the group consisting of polyester-based polyurethanes and polycarbonate-based polyurethanes.
  • Thermoplastic polyurethane is a polymer having a urethane bond in the molecule, generally obtained by a polyaddition reaction of a polyisocyanate such as high-molecular-weight polyol or diisocyanate and a chain extender, using a catalyst such as dibutyltin dilaurate as necessary. When heated, it softens and exhibits fluidity. A hard segment is formed by the reaction of the chain extender and the polyisocyanate, while on the other hand, a soft segment is formed by the reaction of the high-molecular-weight polyol and the polyisocyanate.
  • the high-molecular-weight polyol examples include polyester polyol, polycarbonate polyol, and combinations thereof having not less than two hydroxyl groups and having a number average molecular weight of not less than 400.
  • Polyester polyols form polyester-based polyurethanes
  • polycarbonate polyols form polycarbonate-based polyurethanes.
  • a polyol having both an ester bond and a carbonate bond in the molecule is classified as a polycarbonate polyol.
  • a polyurethane formed by a polyol containing both polyester polyol and polycarbonate polyol is classified as a polycarbonate-based polyurethane. Since there are cases where thermoplasticity is diminished when an excessive crosslinking structure is introduced into a polyurethane, the polyester polyol is preferably a polyester diol, and the polycarbonate polyol is preferably a polycarbonate diol.
  • Polyester polyol may be obtained by, for example, a condensation reaction or an ester exchange reaction of a short-chain polyol having not less than two hydroxyl groups and having a number average molecular weight of not less than 400 with a polybasic acid or alkyl ester, acid anhydride, or acid halide thereof.
  • a short-chain polyamine having not less than two amino groups and having a number average molecular weight of less than 400 may be involved in the condensation reaction or ester exchange reaction.
  • short-chain polyols include dihydric alcohols such as ethylene glycol, propylene glycol, 1,3-propanediol, 1,4-butanediol, 1,3-butanediol, 1,2-butanediol, 2-methyl-1,3-propanediol, 1,5-pentanediol, neopentyl glycol, 3-methyl-1,5-pentanediol, 2,4-diethyl-1,5-pentanediol, 1,6-hexanediol, 2,6-dimethyl-1-octene-3,8-diol, C 7 -C 22 alkane diols, cyclohexanediol, cyclohexane dimethanol, bisphenol A, hydrogenated bisphenol A, 1,4-dihydroxy-2-butene, bishydroxy ethoxy benzene, xylene glycol, bishydroxy ethylene ethylene
  • Short-chain polyols also encompass polyoxyalkylene polyols obtained by adding an alkylene oxide such as ethylene oxide or propylene oxide to these short-chain polyols.
  • Short-chain polyols may be used as one type alone or in a combination of two or more types. Since there are cases where thermoplasticity is diminished when an excessive crosslinking structure is introduced into a polyurethane, a dihydric alcohol is preferably used as the short-chain polyol.
  • polybasic acids include saturated aliphatic dicarboxylic acids such as oxalic acid, malonic acid, succinic acid, methylsuccinic acid, glutaric acid, adipic acid, 1,1-dimethyl-1,3-dicarboxypropane, 3-methyl-3-ethyl glutaric acid, azelaic acid, and sebacic acid; unsaturated aliphatic dicarboxylic acids such as maleic acid, fumaric acid, and itaconic acid; aromatic dicarboxylic acids such as orthophthalic acid, isophthalic acid, terephthalic acid, toluene dicarboxylic acid, and naphthalene dicarboxylic acid; alicyclic dicarboxylic acids such as hexahydrophthalic acid; and other polyhydric carboxylic acids such as dimer acids, hydrogenated dimer acids, and HET acids.
  • saturated aliphatic dicarboxylic acids such as oxalic acid, malonic acid
  • alkyl esters, acid anhydrides, and acid halides of polybasic acids include methyl esters and ethyl esters of the above polybasic acids and the like; oxalic acid anhydride, succinic acid anhydride, maleic acid anhydride, phthalic acid anhydride, 2-C 12 -C 18 alkyl succinic acid anhydride, tetrahydrophthalic acid anhydride, trimellitic acid anhydride, and the like; oxalic acid dichloride, adipic acid dichloride, sebacic acid dichloride, and the like.
  • Polybasic acids may be used as one type alone or in a combination of two or more types.
  • thermoplasticity is diminished when an excessive crosslinking structure is introduced into a polyurethane, a dicarboxylic acid, or alkyl ester, acid anhydride or acid halide thereof is preferably used as the polybasic acid.
  • short-chain polyamines examples include short-chain diamines such as ethylene diamine, 1,3-propane diamine, 1,3-butane diamine, 1,4-butane diamine, 1,6-hexamethylene diamine, 1,4-cyclohexane diamine, 3-aminomethyl-3,5,5-trimethyl cyclohexylamine, 4,4'-dicyclohexylmethane diamine, 2,5(2,6)-bis(aminomethyl)bicyclo[2.2.1]heptane, 1,3-bis(aminomethyl)cyclohexane, hydrazine, and o-, m-, or p-tolylene diamine; short-chain triamines such as diethylene triamine; and short-chain polyamines having four or more amino groups such as triethylene tetramine and tetraethylene pentamine.
  • short-chain diamines such as ethylene diamine, 1,3-propane diamine, 1,3-butane diamine, 1,
  • Short-chain polyamines may be used as one type alone or in a combination of two or more types. Since there are cases where thermoplasticity is diminished when an excessive crosslinking structure is introduced into a polyurethane, a short-chain diamine is preferably used as the short-chain polyamine.
  • Polyester polyols that may be used include vegetable oil-based polyester polyols obtained by condensation reaction of a hydroxycarboxylic acid such as hydroxyl group-containing vegetable oil aliphatic acids; and polycaprolactone polyols and polyvalerolactone polyols obtained by ring-opening polymerization of lactones such as ⁇ -caprolactone and ⁇ -valerolactone and lactides such as L-lactide and D-lactide.
  • a hydroxycarboxylic acid such as hydroxyl group-containing vegetable oil aliphatic acids
  • polycaprolactone polyols and polyvalerolactone polyols obtained by ring-opening polymerization of lactones such as ⁇ -caprolactone and ⁇ -valerolactone and lactides such as L-lactide and D-lactide.
  • polycarbonate polyols examples include ring-opened polymers of ethylene carbonate using a short-chain polyol as an initiator; and amorphous polycarbonate polyols obtained by copolymerizing polycarbonates obtained by reacting the above short-chain dihydric alcohols such as 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, or 1,6-hexanediol with phosgene or diphenyl carbonate, the above short-chain dihydric alcohols, and the above ring-opened polymers.
  • amorphous polycarbonate polyols obtained by copolymerizing polycarbonates obtained by reacting the above short-chain dihydric alcohols such as 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, or 1,6-hexanediol with phosgene or dipheny
  • polyisocyanate examples include aliphatic polyisocyanates, alicyclic polyisocyanates, aromatic polyisocyanates, aromatic aliphatic polyisocyanates, and the like, and multimers (dimers, trimers and the like), biuret-modified products, allophanate-modified products, oxadiazine trione-modified products, and carbodiimide-modified products of these polyisocyanates.
  • Polyisocyanates may be used as one type alone or in a combination of two or more types. Since there are cases where thermoplasticity is diminished when an excessive crosslinking structure is introduced into a polyurethane, a diisocyanate is preferably used as the polyisocyanate.
  • aliphatic polyisocyanates include ethylene diisocyanate, trimethylene diisocyanate, tetramethylene diisocyanate, pentamethylene diisocyanate (PDI), hexamethylene diisocyanate (HDI), octamethylene diisocyanate, nonamethylene diisocyanate, 2,2'-dimethylpentane diisocyanate, 2,2,4-trimethylhexane diisocyanate, decamethylene diisocyanate, butene diisocyanate, 1,3-butadiene-1,4-diisocyanate, 2,4,4-trimethylhexamethylene diisocyanate, 1,6,11-undecamethylene triisocyanate, 1,3,6-hexamethylene triisocyanate, 1,8-diisocyanate-4-isocyanatomethyloctane, 2,5,7-trimethyl-1,8-diisocyanate-5-isocyanatomethyloctane, bis
  • alicyclic polyisocyanates include isophorone diisocyanate, 1,3-bis(isocyanatomethyl)cyclohexane, trans,trans-, trans,cis- and cis,cis-dicyclohexylmethane-4,4'-diisocyanate, and mixtures thereof (hydrogenated MDI), 1,3- or 1,4-cyclohexane diisocyanate and mixtures thereof, 1,3- or 1,4-bis(isocyanatoethyl)cyclohexane, methylcyclohexane diisocyanate, 2,2'-dimethyl dicyclohexylmethane diisocyanate, dimer acid diisocyanate, 2,5-diisocyanatomethyl bicyclo[2.2.1]-heptane, 2,6-diisocyanatomethyl bicyclo[2.2.1]-heptane (NBDI), 2-isocyanatomethyl-2-(3-isocyana
  • aromatic polyisocyanates examples include 2,4-tolylene diisocyanate and 2,6-tolylene diisocyanate, and isomer mixtures of these tolylene diisocyanates (TDI), 4,4'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate, and 2,2'- diphenylmethane diisocyanate, and isomer mixtures of these diphenylmethane diisocyanates (MDI), toluidine diisocyanate (TODI), paraphenylene diisocyanate and naphthalene diisocyanate (NDI).
  • TDI tolylene diisocyanates
  • MDI diphenylmethane diisocyanates
  • TODI toluidine diisocyanate
  • NDI paraphenylene diisocyanate
  • aromatic aliphatic polyisocyanates examples include 1,3- or 1,4-xylylene diisocyanate or mixtures thereof (XDI), and 1,3- or 1,4-tetramethylxylylene diisocyanate or mixtures thereof (TMXDI).
  • chain extenders include dihydric alcohols such as ethylene glycol, propylene glycol, 1,3-propanediol, 1,4-butanediol, 1,3-butanediol, 1,2-butanediol, 2-methyl-1,3-propanediol, 1,5-pentanediol, neopentyl glycol, 3-methyl-1,5-pentanediol, 2,4-diethyl-1,5-pentanediol, 1,6-hexanediol, 2,6-dimethyl-1-octene-3,8-diol, C 7 -C 22 alkane diols, cyclohexanediol, cyclohexane dimethanol, bisphenol A, hydrogenated bisphenol A, 1,4-dihydroxy-2-butene, bishydroxy ethoxy benzene, xylene glycol, bishydroxy ethylene terephthalate
  • Chain extenders also encompass polyoxyalkylene polyols obtained by adding an alkylene oxide such as ethylene oxide or propylene oxide to these short-chain polyols. Chain extenders may be used as one type alone or in a combination of two or more types. Since there are cases where thermoplasticity is diminished when an excessive crosslinking structure is introduced into a polyurethane, a dihydric alcohol is preferably used as the chain extender.
  • the weight average molecular weight of the thermoplastic polyurethane is generally not less than approximately 30,000, not less than approximately 50,000 or not less than approximately 80,000, and not greater than approximately 300,000, not greater than approximately 200,000, or not greater than approximately 150,000.
  • the weight average molecular weight and the number average molecular weight of the thermoplastic polyurethane may be determined by gel permeation chromatography (GPC) using tetrahydrofuran (THF) or N-methylpyrrolidone (NMP) as the solvent, and using standard polystyrene (if the solvent is THF) or standard polymethyl methacrylate (if the solvent is NMP).
  • the polyisocyanate that is the main starting material of the thermoplastic polyurethane is incorporated into the thermoplastic polyurethane in an amount of not less than approximately 20 mass%, not less than approximately 22 mass%, or not less than approximately 25 mass%, and not greater than approximately 40 mass%, not greater than approximately 38 mass%, or not greater than approximately 35 mass% relative to the total amount of thermoplastic polyurethane.
  • the polyurethane thermal adhesive layer one obtained by forming thermoplastic polyurethane into film by molding, extrusion, expansion, or the like may be used.
  • This type of film can be laminated on the design layer, metal brightening layer, substrate layer, and the like via a bonding layer.
  • the design layer, the metal brightening layer, the substrate layer, and the like are adhesive to this film, these layers can be laminated directly onto the film without having a bonding layer therebetween.
  • the polyurethane thermal adhesive layer film may also be formed by coating the thermoplastic polyurethane or a solvent-diluted composition containing the components thereof (polyol and polyisocyanate, and catalyst as necessary) on a liner, removing the solvent, and curing if necessary, and that film may be laminated onto a design layer, metal brightening layer, substrate layer, or the like with a bonding layer therebetween. If the design layer, the metal brightening layer, the substrate layer, and the like are adhesive to the polyurethane thermal adhesive layer film, these layers can be coated or laminated directly onto the polyurethane thermal adhesive layer film without having a bonding layer therebetween.
  • the polyurethane thermal adhesive layer can be formed through multi-layer extrusion with other layers.
  • the fracture strength of the polyurethane thermal adhesive layer is not less than approximately 1 MPa at 135°C. In several embodiments, the fracture strength of the polyurethane thermal adhesive layer at 135°C is not less than approximately 2 MPa, not less than approximately 3 MPa, or not less than approximately 5 MPa, and not greater than approximately 50 MPa, not greater than approximately 30 MPa, or not greater than approximately 20 MPa.
  • the fracture strength of the polyurethane thermal adhesive layer is the value measured when a test piece fractures when pulled at a pulling rate of 300 mm/minute at temperature 135°C using a dumbbell test piece of width 10.0 mm and gauge length 20.0 mm according to JIS K 7311 (1995). Due to the fracture strength of the polyurethane thermal adhesive layer being not less than approximately 1 MPa at 135°C, the heat-expanding film can be prevented from fracturing during operations where the pressure changes at high temperature in IM or TOM.
  • the storage modulus of the polyurethane thermal adhesive layer at 150°C and frequency 1.0 Hz is not less than approximately 5 ⁇ 10 3 Pa and not greater than approximately 5 ⁇ 10 5 Pa. In several embodiments, the storage modulus of the polyurethane thermal adhesive layer at 150°C and frequency 1.0 Hz is not less than approximately 1 ⁇ 10 4 Pa or not less than approximately 2 ⁇ 10 4 Pa, and not greater than approximately 2 ⁇ 10 5 Pa or not greater than approximately 1 ⁇ 10 5 Pa. Due to the storage modulus of the polyurethane thermal adhesive layer at 150°C being in this range, the heat-expanding film can soften to a degree sufficient to adhere to an article without completely losing its shape when heated to the adhesion temperature in IM or TOM.
  • the coefficient of loss tan8 of the polyurethane thermal adhesive layer is not less than approximately 1.0 at 150°C and frequency 1.0 Hz. In several embodiments, the coefficient of loss tan8 of the polyurethane thermal adhesive layer at 150°C and frequency 1.0 Hz is not less than approximately 1.05 or not less than approximately 1.1, and not greater than approximately 5.0 or not greater than approximately 3.0. Due to the coefficient of loss tan8 of the polyurethane thermal adhesive layer at 150°C and frequency 1.0 Hz being not less than approximately 1.0, the heat-expanding film conforms to the recesses and protrusions of the article surface or has sufficient fluidity to embed such recesses and protrusions when heated to the adhesion temperature in IM or TOM.
  • elongation of the polyurethane thermal adhesive layer at 135°C is not less than approximately 200%, not less than approximately 300%, or not less than approximately 500%, and not greater than approximately 2000%, not greater than approximately 1500%, or not greater than approximately 1000%.
  • the ratio of the storage modulus at -20°C and the storage modulus at 110°C (-20°C storage modulus/110°C storage modulus) of the polyurethane thermal adhesive layer measured at frequency 1.0 Hz is not greater than approximately 100, not greater than approximately 80, or not greater than approximately 50, and not less than approximately 1, not less than approximately 2, or not less than approximately 3. Due to the ratio of the storage modulus at -20°C and the storage modulus at 110°C of the polyurethane thermal adhesive layer measured at frequency 1.0 Hz being not greater than 100, interface peeling over time between the polyurethane thermal adhesive layer and other layers it contacts, particularly the metal brightening layer, can be prevented.
  • the ratio of number average molecular weight and weight average molecular weight (weight average molecular weight/number average molecular weight) in the polyurethane thermal adhesive layer is not more than approximately 9.0, and preferably not more than approximately 5.0. Due to the ratio of weight average molecular weight relative to number average molecular weight being not more than approximately 9.0, the occurrence of visual defects (so-called fish-eye) during polyurethane film molding can be suppressed and a heat-expanding film having excellent appearance can be provided. Quality with respect to visual defects may be judged by the number of defects not less than 0.1 mm 2 in size that can be seen on the urethane thermal adhesive layer, where not more than approximately 30 is preferred, and not more than approximately 20 is more preferred.
  • the polyurethane thermal adhesive layer may have a variety of thicknesses, but it is generally not less than approximately 15 ⁇ m, not less than approximately 30 ⁇ m, or not less than approximately 50 ⁇ m, and not more than approximately 1000 ⁇ m, not more than approximately 800 ⁇ m, or not more than approximately 500 ⁇ m.
  • the optional design layer examples include a color layer that exhibits a paint color, metallic color, or the like, a pattern layer that imparts a logo, an image, or a pattern such as a wood grain pattern, stone grain pattern, geometric pattern, or leather pattern to the structure, a relief (embossed pattern) layer in which recesses and protrusions are provided on the surface, and combinations thereof.
  • Pigments that may be used for the color layer by dispersion in a binder resin such as acrylic resin, polyurethane resin or the like are exemplified by inorganic pigments such as titanium oxide, carbon black, chrome yellow, yellow iron oxide, colcothar, red iron oxide, or the like; organic pigments such as phthalocyanine pigments (phthalocyanine blue, phthalocyanine green, or the like), azo lake pigments, indigo pigments, perinone pigments, perylene pigments, quinophthalone pigments, dioxazine pigments, quinacridone pigments (quinacridone red, or the like), or the like; aluminum brightening agents such as aluminum flake, vapor-deposited aluminum flake, metal oxide-coated aluminum flake, colored aluminum flake, or the like; and pearlescent brightening materials such as flake-like mica and synthetic mica coated with a metal oxide such as titanium oxide or iron oxide, or the like.
  • inorganic pigments such as titanium oxide, carbon black, chrome yellow, yellow
  • a film, sheet, metal foil, or the like having a pattern, logo, design, or the like formed by printing such as gravure direct printing, gravure offset printing, inkjet printing, laser printing, or screen printing, coating such as gravure coating, roll coating, die coating, bar coating or knife coating, punching or etching may be used.
  • thermoplastic resin film having a relief form on the surface obtained by a conventional known method such as embossing, scratching, laser processing, dry etching, hot pressing, or the like may be used.
  • a relief layer can be formed by coating a heat-curable or radiation-curable resin such as curable acrylic resin on a release film having a relief form, curing it by heat or radiation, and removing the release film.
  • thermoplastic resin, heat-curable resin and radiation-curable resin used in the relief layer are not particularly limited, but may be fluorine-based resin, polyester-based resin such as PET and PEN, acrylic resin, polyethylene, polypropylene, thermoplastic elastomer, polycarbonate, polyamide, ABS resin, acrylonitrile/styrene resin, polystyrene, vinyl chloride, polyurethane, and the like.
  • the design layer may have a variety of thicknesses, and it is generally not less than approximately 0.5 ⁇ m, not less than approximately 5 ⁇ m, or not less than approximately 20 ⁇ m, and not more than approximately 300 ⁇ m, not more than approximately 200 ⁇ m, or not more than approximately 100 ⁇ m.
  • the heat-expanding film may also contain a metal brightening layer containing a metal such as aluminum, nickel, gold, platinum, chromium, iron, copper, tin, indium, silver, titanium, lead, zinc, or germanium, or alloys or compounds thereof, formed by vacuum deposition, sputtering, ion plating, plating, or the like on a layer that constitutes the heat-expanding film. Because this type of metal brightening layer has high luster, it may be suitably used in a substitute film for chrome plating or the like.
  • the thickness of the metal brightening layer may be, for example, not less than approximately 5 nm, not less than approximately 10 nm, or not less than approximately 20 nm, and not more than approximately 10 ⁇ m, not more than approximately 5 ⁇ m, or not more than approximately 2 ⁇ m.
  • the metal brightening layer is disposed on top of the polyurethane thermal adhesive layer, and the thermoplastic polyurethane contained in the polyurethane thermal adhesive layer is a polycarbonate-based polyurethane.
  • interlayer adhesion is particularly excellent between the metal brightening layer and the polyurethane thermal adhesive layer.
  • resins for example, acrylic resins that include polymethyl methacrylate (PMMA), polyolefins such as polyurethane (PU), polyvinyl chloride (PVC), polycarbonate (PC), acrylonitrile/butadiene/styrene copolymer (ABS), polyethylene (PE), polypropylene (PP), and the like, polyesters such as polyethylene terephthalate (PET), polyethylene naphthalate, and the like, and copolymers such as ethylene/acrylic acid copolymer, ethylene/ethyl acrylate copolymer, ethylene/vinyl acetate copolymer, and the like can be used as a substrate layer, which is an optional element.
  • PMMA polymethyl methacrylate
  • PVC polyvinyl chloride
  • PC polycarbonate
  • ABS acrylonitrile/butadiene/styrene copolymer
  • PET polyethylene terephthalate
  • copolymers such as ethylene/acryl
  • a substrate layer is a supporting layer for the design layer, and provides uniform elongation during molding, and can also function as a protective layer that effectively protects the structure from external punctures and impacts.
  • the substrate layer may have a variety of thicknesses, but from the perspective of imparting the above function to the heat-expanding film without adversely affecting the moldability of the heat-expanding film, it is generally not less than approximately 10 ⁇ m, not less than approximately 20 ⁇ m, or not less than approximately 50 ⁇ m, and not more than approximately 500 ⁇ m, not more than approximately 200 ⁇ m, or not more than approximately 100 ⁇ m.
  • the polyurethane thermal adhesive layer also functions as a substrate layer, and the heat-expanding film does not contain an additional substrate layer.
  • the thickness of the polyurethane thermal adhesive layer of this embodiment is, for example, not less than approximately 10 ⁇ m, not less than approximately 50 ⁇ m, not less than approximately 80 ⁇ m, or not less than approximately 100 ⁇ m, and not more than approximately 1000 ⁇ m, not more than approximately 800 ⁇ m, or not more than approximately 500 ⁇ m.
  • a bonding layer may be used to bond the aforementioned layers.
  • adhesives such as a solvent-type, emulsion-type, pressure-sensitive type, heat-sensitive type, and heat-curable or ultraviolet-curable type adhesives, including acrylics, polyolefins, polyurethanes, polyesters, rubbers, and the like can be used as the bonding layer, and a heat-curable polyurethane adhesive can be advantageously used.
  • the thickness of the bonding layer and is generally not less than approximately 0.05 ⁇ m, not less than approximately 0.5 ⁇ m, or not less than approximately 5 ⁇ m, and not more than approximately 100 ⁇ m, not more than approximately 50 ⁇ m, or not more than approximately 20 ⁇ m.
  • the heat-expanding film of one embodiment contains a thermally transferrable design transfer layer as the design layer.
  • the design transfer layer general contains a thermally adherable surface layer.
  • the design transfer layer may contain a design layer separate from the surface layer, and the surface layer may be a designable layer that contains the pigments, printing inks, and the like described above in regard to the design layer.
  • the surface layer generally contains a thermoplastic resin that softens and exhibits fluidity when heated.
  • the thermoplastic resin may be one type alone or a mixture or blend of two or more types.
  • the glass transition temperature and storage modulus of the thermoplastic resin may be selected as appropriate according to the transfer temperature of the design transfer layer and the application of the final product into which the design transfer layer is incorporated. If the thermoplastic resin is a mixture or blend of two or more types, the glass transition temperature and storage modulus indicate the values measured for the mixture or blend.
  • the thermoplastic resin of the surface layer may be the same or different.
  • Examples of the material that contacts the surface layer include polymeric resins such as acrylic resin, acrylonitrile/butadiene/styrene copolymer (ABS) resin, polycarbonate resin, polyester resin, and mixtures, blends, and combinations thereof, and metals such as tin, indium, and the like, and oxides and alloys of these metals.
  • polymeric resins such as acrylic resin, acrylonitrile/butadiene/styrene copolymer (ABS) resin, polycarbonate resin, polyester resin, and mixtures, blends, and combinations thereof, and metals such as tin, indium, and the like, and oxides and alloys of these metals.
  • the glass transition temperature of the thermoplastic resin may generally be not less than approximately -60°C, preferably not less than approximately -30°C, more preferably not less than approximately 0°C, and even more preferably not less than approximately 20°C, and not greater than approximately 150°C, not greater than approximately 125°C, or not greater than approximately 100°C. Due to the glass transition temperature of the thermoplastic resin being not less than approximately -60°C, excellent adhesive properties can be imparted to the design transfer layer. Due to the glass transition temperature of the thermoplastic resin being not greater than approximately 150°C, the transferability of the design transfer layer can be further improved.
  • the storage modulus of the thermoplastic resin at 50°C can generally be not less than approximately 1.0 ⁇ 10 5 Pa, preferably not less than approximately 2.0 ⁇ 10 6 Pa, and more preferably not less than approximately 5.0 ⁇ 10 6 Pa, and not greater than approximately 1.0 ⁇ 10 10 Pa or not greater than approximately 5.0 ⁇ 10 9 Pa. Due to the storage modulus of the thermoplastic resin at 50°C being not less than approximately 2.0 ⁇ 10 6 Pa, blocking properties of the design transfer layer can be improved. Due to the storage modulus of the thermoplastic resin at 50°C being not greater than approximately 1.0 ⁇ 10 10 Pa, a design transfer layer that is easy to handle can be obtained.
  • the surface layer contains at least one thermoplastic resin selected from the group consisting of vinyl chloride/vinyl acetate copolymer, polyurethane, polyester, (meth)acrylic resin, and phenoxy resin.
  • phenoxy resin means a thermoplastic polyhydroxy polyether synthesized using a bisphenol and epichlorohydrin, and encompasses those having an epoxy group derived from a tiny amount of epichlorohydrin in the molecule (for example, at the terminal).
  • the epoxy equivalent amount of phenoxy resin is higher than that of epoxy resin, for example, not less than 5,000, not less than 7,000 or not less than 10,000.
  • the surface layer contains phenoxy resin.
  • a surface layer that contains phenoxy resin has particularly excellent adhesion to a metal brightening layer containing a metal such as tin, indium, or the like.
  • the surface layer contains phenoxy resin and polyurethane.
  • the temperature required for transfer can be reduced because phenoxy resin is plasticized by polyurethane.
  • the glass transition temperature of the polyurethane contained in the surface layer may be not greater than approximately 60°C, not greater than approximately 40°C, or not greater than approximately 20°C.
  • polyurethane having a glass transition temperature of not greater than approximately 60°C can effectively plasticize the phenoxy resin.
  • the glass transition temperature of the polyurethane may be not less than approximately -80°C.
  • the glass transition temperature of the polyurethane may be determined by the same method as the glass transition temperature of the thermoplastic resin.
  • the polyurethane is a polyester-based polyurethane.
  • compatibility of the polyurethane with phenoxy resin is particularly excellent, and component separation of polyurethane and phenoxy resin hardly occurs even when the design transfer layer is stored for a long period.
  • the mass ratio of phenoxy resin and polyurethane resin is from 99:1 to 30:70, from 99:1 to 40:60, from 99:1 to 50:50, from 90:10 to 30:70, from 90:10 to 40:60, from 90:10 to 50:50, from 80:20 to 30:70, from 80:20 to 40:60, or from 80:20 to 50:50. Due to having this mass ratio, blocking between design transfer layers that contact each other or between the design transfer layer and other articles that contact it can be prevented or reduced.
  • the thickness of the surface layer is generally not less than approximately 0.2 ⁇ m, not less than approximately 0.5 ⁇ m, or not less than approximately 0.8 ⁇ m, and not more than approximately 100 ⁇ m, not more than approximately 50 ⁇ m, or not more than approximately 10 ⁇ m.
  • the heat-expanding film of an embodiment contains a design transfer layer containing a thermally adherable first surface layer and a thermally adherable second surface layer as design layers. Either one of the first surface layer or the second surface layer of the design transfer layer is disposed on the outermost layer side, and the other of the first surface layer or the second surface layer of the design transfer layer is disposed on the polyurethane thermal adhesive layer side.
  • FIG. 4 illustrates a cross-sectional view of such a heat-expanding film (heat-expanding decorative film) 10.
  • the heat-expanding film 10 contains a thermally transferrable design transfer layer 130 containing a thermally adherable first surface layer 131 and a thermally adherable second surface layer 132 as design layers.
  • the first surface layer 131 is disposed on the outermost layer 11 side, and the second surface layer 132 is disposed on the polyurethane thermal adhesive layer 12 side.
  • the first surface layer 131 or the second surface layer 132, or both the first surface layer 131 and second surface layer 132 are designable layers that contain the pigments, printing inks and the like described above in regard to the design layer.
  • the thermally adherable first surface layer and second surface layer of the design transfer layer contain thermoplastic resin, as already described in regard to the surface layer of the design transfer layer.
  • At least one of the first surface layer and second surface layer contains at least one thermoplastic resin selected from the group consisting of vinyl chloride/vinyl acetate copolymer, polyurethane, polyester, (meth)acrylic resin and phenoxy resin.
  • At least one of the first surface layer and second surface layer contains phenoxy resin.
  • a surface layer that contains phenoxy resin has particularly excellent adhesion to a metal brightening layer containing a metal such as tin, indium or the like.
  • At least one of the first surface layer and second surface layer contains phenoxy resin and polyurethane.
  • the temperature required for transfer can be reduced because phenoxy resin is plasticized by polyurethane.
  • the glass transition temperature of the polyurethane contained in the surface layer may be not greater than approximately 60°C, not greater than approximately 40°C, or not greater than approximately 20°C.
  • polyurethane having a glass transition temperature of not greater than approximately 60°C can effectively plasticize the phenoxy resin.
  • the glass transition temperature of the polyurethane may be not less than approximately -80°C.
  • the polyurethane is a polyester-based polyurethane.
  • compatibility of the polyurethane with phenoxy resin is particularly excellent, and component separation of polyurethane and phenoxy resin hardly occurs even when the design transfer layer is stored for a long period.
  • the mass ratio of phenoxy resin and polyurethane resin is from 99:1 to 30:70, from 99:1 to 40:60, from 99:1 to 50:50, from 90:10 to 30:70, from 90:10 to 40:60, from 90:10 to 50:50, from 80:20 to 30:70, from 80:20 to 40:60, or from 80:20 to 50:50. Due to having this mass ratio, blocking between design transfer layers that contact each other or between the design transfer layer and other articles that contact it can be prevented or reduced.
  • the thicknesses of the first surface layer and second surface layer are generally not less than approximately 0.2 ⁇ m, not less than approximately 0.5 ⁇ m, or not less than approximately 0.8 ⁇ m, and not more than approximately 100 ⁇ m, not more than approximately 50 ⁇ m, or not more than approximately 10 ⁇ m.
  • the design transfer layer further contains a design layer between the thermally adherable first surface layer and the thermally adherable second surface layer.
  • the design layer those already described above may be used.
  • the design transfer layer may be produced using conventional known methods such as printing, coating, lamination, or the like.
  • the method for producing a design transfer layer of one embodiment contains a step of preparing a release layer; a step of forming a first surface layer on the release layer by printing by a printing method such as inkjet printing, gravure direct printing, gravure offset printing, screen printing or the like, or coating by a coating means such as a knife coater, bar coater, blade coater, doctor coater, roll coater, cast coater, gravure coater or the like, and, if necessary, heat curing; and a step of forming a second surface layer on the first surface layer or on another layer formed on the first surface layer by the same printing methods or coating means as the first surface layer.
  • a printing method such as inkjet printing, gravure direct printing, gravure offset printing, screen printing or the like
  • a coating means such as a knife coater, bar coater, blade coater, doctor coater, roll coater, cast coater, gravure coat
  • the method for producing the design transfer layer may further contain a step of forming a design layer on the first surface layer or on another layer formed on the first surface layer, before forming the second surface layer.
  • the design layer may be formed using the same printing method or coating means as the first surface layer and the second surface layer.
  • At least one of the first surface layer and the second surface layer may be a designable layer that contains pigments, printing inks and the like. In this manner, a design transfer layer carried on a release layer may be obtained.
  • the design transfer layer may have a variety of thicknesses, and it is generally not less than approximately 0.4 ⁇ m, not less than approximately 1.0 ⁇ m, or not less than approximately 1.6 ⁇ m, and not more than approximately 200 ⁇ m, not more than approximately 100 ⁇ m, or not more than approximately 20 ⁇ m.
  • the design transfer layer may be introduced into the heat-expanding film by the procedure below, for example.
  • a method for producing a heat-expanding film containing a step of preparing a design transfer layer containing a thermally adherable first surface layer and a thermally adherable second surface layer; a step of thermally adhering the first surface layer with the layers constituting the heat-expanding film, such as an outermost layer, a metal brightening layer, a substrate layer, a polyurethane thermal adhesive layer, and the like; and a step of thermally adhering the second surface layer with the other layers that constitute the heat-expanding film, such as an outermost layer, a metal brightening layer, a substrate layer, a polyurethane thermal adhesive layer, and the like.
  • the temperature of thermal adhesion is generally not less than approximately 40°C, not less than approximately 50°C, or not less than approximately 60°C, and not greater than approximately 200°C, not greater than approximately 160°C, or not greater than approximately 140°C.
  • Thermal adhesion may be performed under pressure or not under pressure.
  • the design transfer layer of one embodiment does not require pressure during thermal adhesion.
  • the design transfer layer of this embodiment is advantageously used in inline production such as roll-to-roll style or the like because it does not require a pressuring process or device.
  • a relatively thin design transfer layer can generally be thermally adhered easily at atmospheric pressure.
  • the thickness of the room temperature thermal adhesive design transfer layer may be not less than approximately 0.4 ⁇ m, not less than approximately 1.0 ⁇ m, or not less than approximately 1.6 ⁇ m, and not more than approximately 20 ⁇ m, not more than approximately 10 ⁇ m, or not more than approximately 5 ⁇ m.
  • the outermost layer, polyurethane thermal adhesive layer, substrate layer and/or bonding layer may also include the same coloring material such as inorganic pigments, organic pigments, aluminum brightening material, pearlescent brightening material, and the like described for the design layer.
  • coloring material such as inorganic pigments, organic pigments, aluminum brightening material, pearlescent brightening material, and the like described for the design layer.
  • a heat-expanding film containing a metal brightening layer such as a tin vapor deposition film, indium vapor deposition film, or the like, such as a heat-expanding film used as a substitute film for chrome plating or the like
  • performance of concealing the article that is adhered to can be improved by incorporating the aforementioned pigments into the polyurethane thermal adhesive layer.
  • a tin vapor deposition film may have deposition defects such as pinholes in the vapor deposition film surface, but such defects can be made unnoticeable by coloring the polyurethane thermal adhesive layer.
  • the amount of pigment included in the polyurethane thermal adhesive layer is not less than approximately 0.1 mass%, not less than approximately 0.2 mass%, or not less than approximately 0.5 mass%, and not greater than approximately 50 mass%, not greater than approximately 20 mass%, or not greater than approximately 10 mass% of the polyurethane thermal adhesive layer.
  • the thickness of the heat-expanding film is generally not less than approximately 10 ⁇ m, not less than approximately 25 ⁇ m, or not less than approximately 50 ⁇ m, and not more than approximately 2000 ⁇ m, not more than approximately 1000 ⁇ m, or not more than approximately 500 ⁇ m.
  • the heat-expanding film can be made to sufficiently conform to an article with a complex shape, and thus a structure with excellent appearance can be provided.
  • the scratch resistance of the heat-expanding film can be evaluated through pencil hardness in accordance with JIS K5600-5-4.
  • the pencil hardness of the heat-expanding film of a certain embodiment is 2B or greater when measured by fixing the heat-expanding film on a glass plate with the polyurethane thermal adhesive layer facing the surface of the glass plate and then scratching the outermost layer at a speed of 600 mm/min.
  • the pencil hardness may be not below 6B, not below 5B, not below 4B, or not below 3B.
  • the method for manufacturing the heat-expanding film is not particularly limited.
  • the layers can be manufactured as already described.
  • the heat-expanding film can be manufactured by, for example, forming each layer on a liner such as PET film or the like having a release treated surface, or on another layer that constitutes the heat-expanding film, and then laminating them.
  • the layers can be sequentially laminated on a single liner by repeating a coating process and, as needed, a drying or curing process.
  • the heat-expanding film may also be formed by multi-layer extrusion of the material of each layer.
  • One embodiment of the present disclosure provides a structure containing an article and a heat-expanding film that has been applied to the surface of the article.
  • the structure 1 contains an article 20 covered by a heat-expanding film 10.
  • IM or TOM By applying the heat-expanding film 10 to the article 20 by IM or TOM, a structure in which the heat-expanding film and the article have been integrated can be formed.
  • IM, TOM and extrusion may be performed by conventional known methods.
  • the article may be made of a variety of materials, and materials having a variety of flat surfaces and three-dimensional shapes can be used.
  • the heat-expanding film of the present disclosure exhibits particularly excellent adhesive strength to and can be advantageously used with polycarbonates, acrylonitrile/butadiene/styrene copolymers, or mixtures or blends thereof.
  • a method for applying a heat-expanding film to an article using TOM will be described as an example below in reference to FIGS. 6A to 6E .
  • an exemplary vacuum thermocompression bonding apparatus 30 has a first vacuum chamber 31 and a second vacuum chamber 32 on the bottom and top, respectively, and between these upper and lower vacuum chambers, has a jig on which is set the heat-expanding film 10 to be glued to the article 20 to be adhered to. Furthermore, a partition plate 34 and a pedestal 33 are disposed on a lift table 35 (not illustrated) capable of ascending and descending in the first vacuum chamber 31 on the bottom, and the article 20 such as a three-dimensional object or the like is set on this pedestal 33.
  • a commercially available product for example, a two-sided vacuum molding machine (manufactured by Fu-se Vacuum Forming Ltd.), may be used.
  • the heat-expanding film 10 is first set between the upper and lower vacuum chambers in a state in which the first vacuum chamber 31 and the second vacuum chamber 32 of the vacuum thermocompression bonding apparatus 30 are open to atmospheric pressure.
  • the article 20 is set on the pedestal 33 in the first vacuum chamber 31.
  • the first vacuum chamber 31 and the second vacuum chamber 32 are closed, the respective chambers are depressurized, and a vacuum (for example, approximately 0 atm when atmospheric pressure is taken as 1 atm) is drawn inside each chamber.
  • the film is heated after or simultaneously with drawing of the vacuum.
  • the lift table 35 is raised, and the article 20 is pushed up to the second vacuum chamber 32.
  • the heating can be performed, for example, using a lamp heater built into a ceiling part of the second vacuum chamber 32.
  • the heating temperature generally may be not less than approximately 50°C and not greater than approximately 180°C, and preferably not less than approximately 130°C or not greater than approximately 160°C.
  • the degree of vacuum of the vacuum atmosphere generally may be not greater than approximately 0.10 atm, not greater than approximately 0.05 atm, or not greater than approximately 0.01 atm, when atmospheric pressure is taken as 1 atm.
  • the heated heat-expanding film 10 is pressed against the surface of the article 20 and expanded.
  • the interior of the second vacuum chamber 32 is pressurized to an appropriate pressure (for example, from 3 atm to 1 atm), as illustrated in FIG. 6D . Due to the pressure difference, the heat-expanding film 10 is firmly adhered to the exposed surface of the article 20 and is expanded to conform to the three-dimensional shape of the exposed surface, and thereby forms a firmly adhered coating on the article surface.
  • the interior of the second vacuum chamber 32 can be pressurized in that state, and the exposed surface of the article 20 can be covered with the heat-expanding film 10.
  • the lower and upper first vacuum chamber 31 and second vacuum chamber 32 are again opened to atmospheric pressure, and the article 20 covered with the heat-expanding film 10 is removed.
  • the edges of the heat-expanding film 10 adhered to the surface of the article 20 are trimmed, and the TOM process is complete.
  • the heat-expanding film 10 wraps around to the rear surfaces 21 on the ends of the article 20 and neatly covers the exposed surface, and thus a structure 1 covered with a good wrapping can be obtained.
  • the maximum area extension percentage of the heat-expanding film after molding is generally not less than approximately 50%, not less than approximately 100%, or not less than approximately 200%, and not greater than approximately 1000%, not greater than approximately 500%, or not greater than approximately 300%.
  • the maximum area extension percentage means the value at the location of highest area extension percentage in the heat-expanding film on the entire article surface. For example, when a flat film is affixed to a three-dimensional article by TOM, the portion of the film that first affixes to the article hardly expands and has an area extension percentage of nearly 0%, while the ends that are affixed last are expanded significantly and achieve an area extension percentage of 200% or more, and thus the area extension percentage varies widely depending on the location.
  • the acceptability of molding is determined based on whether or not a defect occurs, such as non-conformance to the article or a tear in the film, in a portion that was expanded the most, the area extension percentage in the portion that was expanded the most, that is, the maximum area extension percentage, serves as the substantial index for the acceptability of the molded product, rather than the average area extension percentage of the overall molded product.
  • the maximum area extension percentage is determined by, for example, printing 1-mm squares on the entire surface of the heat-expanding film before molding and then measuring the change in the areas thereof after molding, or by measuring the thickness of the heat-expanding film before and after molding.
  • the heat-expanding film of the present disclosure may be used for the purpose of decoration of automotive parts, household appliances, railroad cars, building materials, and the like, in various molding techniques such as TOM, IM, extrusion, and the like, but it can be used particularly advantageously in TOM.
  • Polyurethane films used as the polyurethane thermal adhesive layer were prepared by the following procedures.
  • Polycarbonate diol of number average molecular weight 1000 was prepared by adding 0.00072 parts of lead acetate trihydrate as a catalyst to 53.0 parts of 3-methyl-1,5-pentanediol and 47.0 parts of ethylene carbonate, and reacting for 16 hours at 160°C. 64.0 parts of the above polycarbonate diol, 8.0 parts of 1,4-butanediol, 28.0 parts of 1,6-hexamethylene diisocyanate, and 0.01 parts of dibutyltin dilaurate were mixed, and after reacting for 3 hours at 180°C, a film 100 ⁇ m thick was produced using a compression molder.
  • the molecular weight of the obtained polyurethane measured by GPC was number average molecular weight 28,000 and weight average molecular weight 89,000.
  • Polyester polyol of number average molecular weight 500 was prepared by adding 40 ppm of titanium tetrabutyrate as a catalyst to 21.6 parts of adipic acid and 29.6 parts of 1,4-butanediol, and performing an esterification reaction at 240°C. 56.0 parts of the above polyester polyol, 15.0 parts of Kuraray polyol PMHC-1050, 2.0 parts of 1,6-hexanediol, 27.0 parts of 1,6-hexamethylene diisocyanate and 0.01 parts of dibutyltin dilaurate were mixed, and after reacting for 3 hours at 180°C, films 50 ⁇ m thick and 100 ⁇ m thick were produced using a compression molder.
  • the molecular weight of the obtained polyurethane measured by GPC was number average molecular weight 46,000 and weight average molecular weight 120,000.
  • Polyester polyol of number average molecular weight 1200 was prepared by adding 40 ppm of titanium tetrabutyrate as a catalyst to 49.0 parts of adipic acid, 14.5 parts of isophthalic acid and 36.5 parts of 1,4-butanediol, and performing an esterification reaction at 240°C. 63.0 parts of the above polyester polyol, 5.0 parts of 1,4-butanediol, 32.0 parts of dicyclohexylmethane-4,4'-diisocyanate, and 0.01 parts of dibutyltin dilaurate were mixed, and after reacting for 3 hours at 180°C, a film 150 ⁇ m thick was produced using a compression molder.
  • the molecular weight of the obtained polyurethane measured by GPC was number average molecular weight 51,000 and weight average molecular weight 120,000.
  • the characteristics of the obtained polyurethane films and heat-expanding films were evaluated using the following test methods.
  • the molecular weight of the polyurethane films is determined by gel permeation chromatography (GPC) under the following conditions.
  • Tensile strength and elongation of the polyurethane films are determined according to JIS K 7311 (1995) using the following conditions.
  • Initial adhesive property is evaluated based on the cross-cut tape test of JIS K5400: 1990 (out of print). Specifically, using TOM, the heat-expanding film is adhered to a PC/ABS sheet (CK43 black, manufactured by TechnoPolymer Co., Ltd., Minato-ku, Tokyo, Japan) such that the area extension percentage at molding temperature 135°C is 100%, and then, using a cutter, slits are made in the film in a cross-cut pattern at 1 mm intervals to form 100 segments.
  • CK43 black manufactured by TechnoPolymer Co., Ltd., Minato-ku, Tokyo, Japan
  • TM Sellotape (CT405AP-18, manufactured by Nichiban Co., Ltd., Bunkyo-ku, Tokyo, Japan) is pressed on top of the film in which slits were made in a cross-cut pattern, and is then pulled in the 90-degree direction.
  • the number of cross-cut segments remaining on the film is counted and used as the value of adhesive property evaluation. If the number of remaining segments is 100 (100/100), it is evaluated as "best,” and if 90 or more (90/100 or more), it is evaluated as "good.”
  • the heat-expanding film is adhered to a PC/ABS sheet (CK43 black, manufactured by TechnoPolymer Co., Ltd., Minato-ku, Tokyo, Japan) such that the area extension percentage at molding temperature 135°C is 100%. After molding by TOM, the appearance is observed after undergoing the following heat cycles.
  • CK43 black manufactured by TechnoPolymer Co., Ltd., Minato-ku, Tokyo, Japan
  • the heat-expanding film is adhered to a PC/ABS sheet (CK43 black, manufactured by TechnoPolymer Co., Ltd., Minato-ku, Tokyo, Japan) such that the area extension percentage at molding temperature 135°C is 100%.
  • the obtained laminate is cut to a width of 25 mm and length of 50 mm to produce a test piece.
  • the adhesive strength is taken as the average of values measured when heat-expanding films are peeled from the PC/ABS sheet by pulling the test piece in the 180-degree direction at temperature 23°C at a pulling rate of 300 mm/minute and distance between grips of approximately 50 mm, using a Tensilon (TM) universal testing machine RTC-1325A (load cell 50 N, UR-50N-3) (manufactured by Orientec Co., Ltd., Toshima-ku, Tokyo, Japan).
  • TM Tensilon
  • a film containing an acrylic resin outermost layer, a bonding layer, a metal vapor deposition film and a polyurethane thermal adhesive layer in that order was produced.
  • An acrylic copolymer of methyl methacrylate (MMA)/2-hydroxyethyl methacrylate (HEMA) 97 mass%/3 mass% was prepared by general solution polymerization, and obtained in the form of an ethyl acetate/butyl acetate solution containing 35 mass% solids.
  • isocyanate crosslinking agent Duranate (TM) TPA-100 was added to result in 2.7 mass% solids relative to the copolymer.
  • the obtained solution was coated on a polyester film having a thickness of 75 ⁇ m and then dried for 10 minutes at 100°C and then 10 minutes at 150°C. In this manner, an acrylic resin outermost layer 50 ⁇ m thick was obtained on a polyester film.
  • Tin was vapor-deposited on a polyurethane thermal adhesive layer.
  • a polyurethane thermal adhesive layer was pre-laminated on a polyester film 50 ⁇ m thick, and during the deposition process, it was loaded on this film. Deposition conditions are as follows.
  • polyester polyol SEIKABOND (TM) E-295NT and 2.9 parts by mass of isocyanate curing agent C-55 were mixed, and this was coated onto the acrylic resin outermost layer prepared as described above. It was heated for 3 minutes in a 100°C oven, and a bonding layer 15 ⁇ m thick was formed on the acrylic resin outermost layer.
  • the acrylic surface resin layer and the polyurethane thermal adhesive layer were placed such that the bonding layer and the metal vapor deposition film were facing each other, and these layers were laminated at 50°C and nip pressure 2.0 kgf to form a film.
  • a heat-expanding decorative film containing a thermally transferrable design transfer layer was produced by the following procedure.
  • gravure ink VTP-NT CD black (A) was printed in a prescribed pattern using gravure printing to form a design layer.
  • the thickness of the design layer measured by a thickness gauge was approximately 2 ⁇ m.
  • the same solution as the first surface layer was coated onto the design layer using a #12 Meyer bar, and it was dried for 3 minutes at 60°C to form a thermally adherable second surface layer.
  • the thickness of the thermally adherable second surface layer measured by a thickness gauge was approximately 2 ⁇ m.
  • a design transfer sheet containing a polyester film (release layer) and a design transfer layer releasably mounted on the polyester film was produced.
  • the design transfer layer contained, in order from the polyester film side, a first surface layer, a design layer and a second surface layer.
  • the second surface layer of the design transfer layer and the polyurethane thermal adhesive layer not having a tin vapor deposition film or the polyurethane thermal adhesive layer having a tin vapor deposition film were placed facing each other, and laminates were formed by gluing them using a roll laminator at temperature 130°C and pressure 2 kgf.
  • the polyester films were peeled from the obtained laminates, and the exposed first surface layer and an acrylic film Technolloy (TM) S014G were placed facing each other, and two types of evaluation sample were produced by gluing them using a roll laminator at temperature 130°C and pressure 2 kgf.
  • Initial adhesive property was evaluated using the evaluation samples. The appearance of the samples produced for use in initial adhesive property evaluation was good. The initial adhesive property was 100/100 for both the polyurethane film not having a tin vapor deposition film and the polyurethane film having a tin vapor deposition film. In the adhesive property evaluation, peeling occurred between the tape and the acrylic film, and no interlayer peeling was seen.
  • Samples for initial adhesive property evaluation were prepared in the same manner as above. The obtained samples were put in a 110°C oven for 500 hours and then removed and left to stand for 1 day at room temperature, after which appearance and adhesive property were evaluated in the same manner. The appearance of the samples after the heated acceleration test was good, and when adhesive property was tested, it was 100/100 for both the polyurethane film not having a tin vapor deposition film and the polyurethane film having a tin vapor deposition film. In the adhesive property evaluation, peeling occurred between the tape and the acrylic film, and no interlayer peeling was seen.
  • the heat-expanding film is observed from the urethane thermal adhesive layer, and the number of defects not less than 0.1 mm 2 in size that can be seen in 1.0 m 2 of the heat-expanding film is counted.
  • Polyurethane films used as a polyurethane thermal adhesive layer were prepared by the following procedures.
  • Polyester polyol of number average molecular weight 500 was prepared by adding 40 ppm of titanium tetrabutyrate as a catalyst to 21.6 parts of adipic acid and 29.6 parts of 1,4-butanediol, and performing an esterification reaction at 240°C. 56.0 parts of the above polyester polyol, 15.0 parts of Kuraray polyol PMHC-1050, 2.0 parts of 1,6-hexanediol, 27.0 parts of 1,6-hexamethylene diisocyanate and 0.005 parts of dibutyltin dilaurate were mixed, and after reacting for 4 hours at 170°C, films 50 ⁇ m thick were produced using a compression molder.
  • the molecular weight of the obtained polyurethane measured by GPC was number average molecular weight 27,000 and weight average molecular weight 134,000.
  • Polyester polyol of number average molecular weight 500 was prepared by adding 40 ppm of titanium tetrabutyrate as a catalyst to 21.6 parts of adipic acid and 29.6 parts of 1,4-butanediol, and performing an esterification reaction at 240°C. 56.0 parts of the above polyester polyol, 15.0 parts of Kuraray polyol PMHC-1050, 2.0 parts of 1,6-hexanediol, 27.0 parts of 1,6-hexamethylene diisocyanate and 0.005 parts of dibutyltin dilaurate were mixed, and after reacting for 4 hours at 175°C, films 50 ⁇ m thick were produced using a compression molder.
  • the molecular weight of the obtained polyurethane measured by GPC was number average molecular weight 27,000 and weight average molecular weight 126,000.
  • Polyester polyol of number average molecular weight 500 was prepared by adding 40 ppm of titanium tetrabutyrate as a catalyst to 21.6 parts of adipic acid and 29.6 parts of 1,4-butanediol, and performing an esterification reaction at 240°C. 56.0 parts of the above polyester polyol, 15.0 parts of Kuraray polyol PMHC-1050, 2.0 parts of 1,6-hexanediol, 27.0 parts of 1,6-hexamethylene diisocyanate and 0.005 parts of dibutyltin dilaurate were mixed, and after reacting for 3 hours at 185°C, films 50 ⁇ m thick were produced using a compression molder.
  • the molecular weight of the obtained polyurethane measured by GPC was number average molecular weight 23,000 and weight average molecular weight 112,000.
  • Polyester polyol of number average molecular weight 500 was prepared by adding 40 ppm of titanium tetrabutyrate as a catalyst to 21.6 parts of adipic acid and 29.6 parts of 1,4-butanediol, and performing an esterification reaction at 240°C. 56.0 parts of the above polyester polyol, 15.0 parts of Kuraray polyol PMHC-1050, 2.0 parts of 1,6-hexanediol, 27.0 parts of 1,6-hexamethylene diisocyanate and 0.002 parts of dibutyltin dilaurate were mixed, and after reacting for 8 hours at 160°C, films 50 ⁇ m thick were produced using a compression molder.
  • the molecular weight of the obtained polyurethane measured by GPC was number average molecular weight 25,000 and weight average molecular weight 216,000.
  • Polyester polyol of number average molecular weight 500 was prepared by adding 40 ppm of titanium tetrabutyrate as a catalyst to 21.6 parts of adipic acid and 29.6 parts of 1,4-butanediol, and performing an esterification reaction at 240°C. 56.0 parts of the above polyester polyol, 15.0 parts of Kuraray polyol PMHC-1050, 2.0 parts of 1,6-hexanediol, 27.0 parts of 1,6-hexamethylene diisocyanate and 0.005 parts of dibutyltin dilaurate were mixed, and after reacting for 4 hours at 160°C, films 50 ⁇ m thick were produced using a compression molder.
  • the molecular weight of the obtained polyurethane measured by GPC was number average molecular weight 22,000 and weight average molecular weight 151,000.
  • a film containing an outermost layer, a substrate layer, a thermally transferrable design transfer layer, a metal vapor deposition film and a polyurethane thermal adhesive layer in that order was produced.
  • a two-layer film of different composition ratios of vinylidene fluoride and PMMA ⁇ (6 ⁇ m outer layer made of a mixture of 80 wt% polyvinylidene fluoride and 20 wt% PMMA)/(24 ⁇ m inner layer made of a mixture of 20 wt% polyvinylidene fluoride and 80 wt% PMMA) ⁇ (Denka DX film 14S0230 manufactured by Denki Kagaku Kogyo K.K., thickness 30 ⁇ m) was prepared.
  • acrylic film TechnoloyTM S014G was prepared as the substrate layer.
  • gravure ink VTP-NT CD black (A) was printed in a prescribed pattern using gravure printing to form a design layer.
  • the thickness of the design layer measured by a thickness gauge was approximately 2 ⁇ m.
  • the same solution as the first surface layer was coated onto the design layer using a #12 Meyer bar, and it was dried for 3 minutes at 60°C to form a thermally adherable second surface layer.
  • the thickness of the thermally adherable second surface layer measured by a thickness gauge was approximately 2 ⁇ m.
  • Tin was vapor-deposited on a polyurethane thermal adhesive layer.
  • a polyurethane thermal adhesive layer was pre-laminated on a polyester film 50 ⁇ m thick, and during the deposition process, it was loaded on this film. Deposition conditions are as follows.
  • the thermally transferrable design transfer layer and the polyurethane thermal adhesive layer were disposed such that the thermally transferrable design transfer layer and the metal vapor deposition layer were in contact, and these layers were laminated at 115°C.
  • the polyester film was peeled from the obtained laminate, and on the exposed surface, the substrate layer and the outermost layer were disposed in that order and laminated at 105°C to produce a film.

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Claims (9)

  1. Folie, die einen Gegenstand mit einer dreidimensionalen Form durch Wärmeausdehnung bedecken kann,
    wobei die Folie Folgendes umfasst:
    eine äußerste Schicht, die auf einer äußersten Oberfläche angeordnet ist; und
    eine thermische Polyurethan-Kleberschicht, die ein thermoplastisches Polyurethan, ausgewählt aus der Gruppe bestehend aus Polyurethanen auf Polyester-Basis und Polyurethanen auf Polycarbonat-Basis, enthält und während der Wärmeausdehnung mit dem Gegenstand thermisch verklebt wird; wobei
    die Bruchfestigkeit der thermischen Polyurethan-Kleberschicht nicht weniger als 1 MPa bei 135 °C beträgt und der Speichermodul bei 150 °C und einer Frequenz von 1,0 Hz von 5 × 103 Pa bis 5 × 105 Pa beträgt und ein Verlustkoeffizient (tanö) nicht weniger als 0,1 beträgt, wobei der Verlustkoeffizient (tanö) das Verhältnis von Scherverlustmodul G"/ Scherspeicherelastizitätsmodul G', durchgeführt im Schermodus bei 150 °C und bei einer Frequenz von 1,0 Hz, ist.
  2. Folie nach Anspruch 1, wobei ein Verhältnis eines Speichermoduls bei -20 °C und eines Speichermoduls bei 110 °C (-20 °C Speichermodul/110 °C Speichermodul) der thermischen Polyurethan-Kleberschicht gemessen bei
    einer Frequenz von 1,0 Hz ist nicht größer als 100 ist.
  3. Folie nach Anspruch 1 oder 2, wobei das thermoplastische Polyurethan ein Polyurethan auf Polycarbonatbasis ist und ferner eine Metallaufhellungsschicht umfasst, die auf der thermischen Polyurethan-Kleberschicht zwischen der äußersten Schicht und der thermischen Polyurethan-Kleberschicht angeordnet ist.
  4. Folie nach einem der Ansprüche 1 bis 3, wobei Polyisocyanat in das thermoplastische Polyurethan in einer Menge von 20 Masse-% bis 40 Masse -%, bezogen auf das gesamte thermoplastische Polyurethan, eingearbeitet ist.
  5. Folie nach einem der Ansprüche 1 bis 4, wobei ein Verhältnis des gewichtsgemittelten Molekulargewichts zum zahlengemittelten Molekulargewicht (gewichtsgemitteltes Molekulargewicht/zahlengemitteltes Molekulargewicht) in der thermischen Polyurethan-Kleberschicht nicht größer als 9,0 ist.
  6. Folie nach einem der Ansprüche 1 bis 5, wobei die thermische Polyurethan-Kleberschicht gefärbt ist.
  7. Dekorfolie, die einen Gegenstand mit einer dreidimensionalen Form durch Wärmeausdehnung bedecken kann,
    wobei die Folie Folgendes umfasst:
    eine äußerste Schicht, die auf einer äußersten Oberfläche angeordnet ist;
    eine thermische Polyurethan-Kleberschicht, die ein thermoplastisches Polyurethan, ausgewählt aus der Gruppe bestehend aus Polyurethanen auf Polyester-Basis und Polyurethanen auf Polycarbonat-Basis, enthält und während der Wärmeausdehnung mit dem Gegenstand thermisch verbunden wird; und
    eine Entwurfsschicht, die zwischen der äußersten Schicht und der thermischen Polyurethan-Kleberschicht angeordnet ist; wobei
    die Bruchfestigkeit der thermischen Polyurethan-Kleberschicht nicht weniger als 1 MPa bei 135 °C beträgt und der Speichermodul bei 150 °C und einer Frequenz von 1,0 Hz von 5 × 103 Pa bis 5 × 105 Pa beträgt und ein Verlustkoeffizient (tanö) nicht weniger als 0,1 beträgt, wobei der Verlustkoeffizient (tanö) das Verhältnis von Scherverlustmodul G"/ Scherspeicherelastizitätsmodul G', durchgeführt im Schermodus bei 150 °C und bei einer Frequenz von 1,0 Hz, ist.
  8. Dekorfolie nach Anspruch 7, die eine thermisch übertragbare Entwurfsübertragungsschicht als Entwurfsschicht enthält.
  9. Gegenstand, der durch Abdecken und Integrieren eines Gegenstandes mit der in einem der Ansprüche 1 bis 6 beschriebenen Folie oder der in Anspruch 7 oder 8 beschriebenen Dekorfolie erhalten wird.
EP15826100.8A 2014-12-24 2015-12-21 Folie und dekorative folie zur abdeckung eines artikels mit dreidimensionaler form durch wärmeausdehnung Active EP3237199B1 (de)

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